KOMATSU D41E-6 D41P-6 BULLDOZER Operation Maintenance Manual

Operation & Maintenance Manual SEAM0081 02 D41E I D41 Pi BULLDOZER SERIAL NUMBERS II41 E-6 - B20501 andup D41P-6 - 820501 This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. March 1997 Copyright 1997 Komatsu America International Company

1. FOREWORD This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require. a WARNING Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operators and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in a readily available place near the machine (on machines with cab, there is a door pocket to hold the manual), and have all personnel involved in working on the machine read the manual periodically. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. The procedures and precautions given in this manual apply only to intended uses of the machine. if you use your machine for any unintended uses that are not specifically prohibited, you must be stire that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine. The description of safety is given in SAFETY INFORMATION on page O-2 and in SAFETY from page l-l. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. O-l

2. SAFETY INFORMATIO’N Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. To identify safety messages in this manual and on machine labels, the following signal words are used. A DANGER - This word is used on safety messages and safety labels where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine. A WARNING - A CAUTION - NOTICE - This word is used on safety messages and safety labels where there is a potentially dangerous situation which could result in serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine. This word is used on safety messages and safety labels for hazards which could result in minor or moderate injury if the hazard is not avoided. This word might also be word for hazards where the only result could be damage to the machine. This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine. Safety precautions are described in SAFETY from page l-l. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your Komatsu distributor. o-2

3. INTRODUCTION 3.1 INTENDED USE This Komatsu BULLDOZER is designed to be used mainly for the following work: l Dozing l Smoothing l Cutting into hard or frozen ground or ditching. l Felling trees, removing stumps See the section “12.15 WORK POSSIBLE USING BULLDOZER” for further details. 3.2 FEATURES l Joystick for easy lever operations l Pressurized, sealed cab with air conditioner for pleasant operations l Simple check operations using monitor panel l High power engine with turbocharger, combined with long track give high operating performance l Large angle blade for case of transportation l Low noise and stylish form and coloring for operations without problem even in residential areas l Engine can be stopped with starting switch key 3.3 BREAKING IN THE MACHINE Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.) During breaking in: l Idle the engine for 5 minutes after starting it up. l Avoid operation with heavy loads or at high speeds. l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency. The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user. Operations that are prohibited in this manual must never be carried out under any circumstances. o-3

4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION This is at the front bottom right of the operator’s seat. This is on the side of the front gear engine on the left side of the machine. 4.2 ENGINE SERIAL NO. PLATE POSITION housing at the front of the 4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No.: Engine serial No.: Distributor name: Address: Service personnel for your machine: Phone: REMARKS o-4

5. CONTENTS 1. Foreword .... ...... ...... ...... ........ ...... ... .... .... ........... ..... .. ..... .. .. .............. ......... ... . ............ ........................... 2. Safety information . ..... .... .... ........... ... ...... ...... ...... ... ... ...... .......... ............... ....... ....... ... ...... .... .... .. ... ..... 3. Introduction .... ...... .. .......... .............. ... ....... .... .. ...... .... ... ..... .................. ...... ............ ....... ..... .................. 4. Location of plates, table to enter serial No. and distributor .... ...... ....... .......... ... .... ..... .... ... ........ SAFETY 6. General precautions .. .. ...... ...... ... ............. .. ... ......... ... ....... .. ... ................ .... ........ ............... .. ..... . ... ....... I- 2 7. Precautions during operation .......................................................................................................... I- 7 7.1 Before starting engine.. ........................................................................................................... I- 7 7.2 After starting engine.. .............................................................................................................. I- 9 7.3 Transportation .......................................................................................................................... 1-15 7.4 Battery ....................................................................................................................................... 1-16 7.5 Towing ...................................................................................................................................... 1-18 8. Precautions for maintenance ........................................................................................................... 8.1 Before carrying out maintenance .......................................................................................... 8.2 During maintenance ................................................................................................................ 9. Position for attaching safety labels ................................................................................................ 1-28 9.1 Position for attaching safety labels ....................................................................................... l-28 OPERATION 10. 11. o- 1 o- 2 O-3 o- 4 1-19 1-19 l-23 General view ...................................................................................................................................... 2- 2 10.1 General view of machine ........................................................................................................ 2- 2 10.2 General view of controls and gauges ................................................................................... 2- 3 Explanation of components ............................................................................................................. 2- 5 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 Front panel (meters, lamps, switches) .................................................................................. Switches .................................................................................................................................... Control levers, pedals .............................................................................................................. Fuse box ................................................................................................................................... Grease pump holder ............................................................................................................... Door-open lock (machines equipped with cab) ................................................................... Opening and closing rear window (machines equipped with cab) .................................. Cap with lock.. .......................................................................................................................... Hot and cool box (machines equipped with cab). ............................................................... Tool box .................................................................................................................................... Using car radio (machines equipped with cab, car radio) ................................................. Using car stereo (machines equipped with cab) ................................................................. Handling air conditioner (machines equipped with cab) .................................................... Handling heater (machines equipped with cab) .................................................................. Power outlets ........................................................................................................................... 2- 6 2-17 2-20 2-26 2-27 2-27 2-27 2-28 2-28 2-28 2-29 2-33 2-39 2-43 2-44 o-5

12. Operation .... .......... ........ .... ........ .. .......... ............. ........... ........ .......... ..... ........ ..... .. ........ ........................ 2-45 13. Transportation .......... .. ..... ...... ... .. ... ......... ...... ......... .......... ........ ......... .. ... .... ~ ....... ...... .. .. ....... ... ............ 2-80 13.1 13.2 13.3 13.4 Loading, unloading work ........................................................................................................ Precautions for loading ........................................................................................................... Precautions for transportation ................................................................................................ Removing cab (machines equipped with cab) ..................................................................... 2-80 2-81 2-82 2-83 14. Cold 14.1 14.2 14.3 weather operation .................................................................................................................... Precautions for low temperature ........................................................................................... After completion of work.. ...................................................................................................... After cold weather ................................................................................................................... 2-84 2-84 2-86 2-86 15. Long-term storage ............................................................................................................................. 2-87 15.1 Before storage .......................................................................................................................... 2-87 15.2 During storage ......................................................................................................................... 2-87 15.3 After storage.. ........................................................................................................................... 2-87 16. Troubleshooting ................................................................................................................................. 16.1 After running out of fuel.. ....................................................................................................... 16.2 If battery is discharged ........................................................................................................... 16.3 Other trouble ............................................................................................................................ 2-88 2-88 2-88 2-91 Ii.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 12.14 12.15 12.16 Check before starting engine ............................................. .: .................................................. Starting engine.. ....................................................................................................................... Operations and checks after starting engine.. ...................................................................... Moving machine ...................................................................................................................... Shifting gear ............................................................................................................................. Shifting between forward and reverse.. ................................................................................ Steering machine ..................................................................................................................... Stopping machine.. .................................................................................................................. Precautions for operation ....................................................................................................... Parking machine ...................................................................................................................... Check after finishing work ...................................................................................................... Stopping engine ....................................................................................................................... Check after stopping engine ................................................................................................... Locking ...................................................................................................................................... Work possible using bulldozer.. ............................................................................................. Tips for longer undercarriage life .......................................................................................... 2-45 2-57 2-61 2-63 2-64 2-65 2-66 2-68 2-69 2-71 2-72 2-73 2-74 2-74 2-75 2-77 O-6

5. CONTENTS MAINTENANCE 17. Guides to maintenance ..................................................................................................................... 19. Outlines of service ............................................................................................................................ 19. 20. 21. 22. 23. 24. 18.1 Outline of oil, fuel, coolant ..................................................................................................... 18.2 Relating to electric system ..................................................................................................... Wear parts list ................................................................................................................................... Use of fuel, coolant and lubricants according to ambient temperature ................................... Standard tightening torques for bolts and nuts ........................................................................... 21 .I Introduction of necessary tools.. ............................................................................................ 21.2 Torque list.. ............................................................................................................................... Periodic replacement of safety critical parts ................................................................................. Maintenance schedule chart ......... .I.. ............................................................................................... Service Procedure .............................................................................................................................. 24.1 When required ....................................................... *. ................................................................ 24.2 Check before starting .............................................................................................................. 24.3 Every 50 hours service ............................................................................................................ 24.4 Every 250 hours service .......................................................................................................... 24.5 Every 500 hours service.. ........................................................................................................ 24.6 Every 1000 hours service ........................................................................................................ 24.7 Every 2000 hours service ........................................................................................................ 24.8 Every 4000 hours service ........................................................................................................ SPECIFICATIONS 25. Specifications .... ...... .. ................... ........... ... ....... ......... ... ...... .... ...... .. ........ .................... ...*................... OPTIONS, ATTACHMENTS 26. 27. General precautions ........................................................................................................................... 26.1 Precautions related to safety .................................................................................................. Handling deluxe seat ......................................................................................................................... 3- 2 3- 4 3- 4 3- 6 3- 7 3- 8 3-12 3-12 3-13 3-14 3-17 3-20 3-20 3-33 3-39 3-40 3-47 3-48 3-59 3-58 4- 2 5- 2 5- 2 5- 3 o-7

MEMO O-8

SAFETY result in serious injury or death. This safety section also contains precautions for optional equipment and attachments. l-l

KOMATSU D41E-6 D41P-6 BULLDOZER Operation Maintenance Manual

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